Adjustable shipping container for spindled contents

ABSTRACT

A shipping container includes a first cover and a first bearer. The first cover includes sidewalls and a first plurality of ribs defined in the sidewalls. The first load bearer is positioned in a first pair of the first plurality of ribs and defines a first support surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 60/616,536 filed on Oct. 6, 2004.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable

BACKGROUND OF THE INVENTION

The invention relates generally to the field of packaging, and moreparticularly, to an adjustable shipping container for spindled contents.

During shipment in transport vehicles, goods must be protected to avoiddamage. Various shipping containers have been devised to protect itemsduring handling and shipping. One type of product that requires suchprotection is a material packaged in the form of rolls. Exemplaryproducts include plastic film, paper, fabric, or mesh rolled on a hollowpaper fiber or plastic core.

Typically, rolled products are moved and stored in steel racks or woodencrates. These packaging techniques have various shortcomings. Woodencrates are typically custom made according to the size of the shippeditem on-site. Certain countries do not accept products shipped in woodencrates. Also, wooden crates exhibit low durability and can seldom bereused, giving rise to additional disposal costs. Steel racks do notenclose the product and do not easily condense for return shipment.Additionally, due to their weight, steel racks reduce the overallpayload of the product being shipped in a truck or overseas cargocontainer.

This section of this document is intended to introduce various aspectsof art that may be related to various aspects of the present inventiondescribed and/or claimed below. This section provides backgroundinformation to facilitate a better understanding of the various aspectsof the present invention. It should be understood that the statements inthis section of this document are to be read in this light, and not asadmissions of prior art. The present invention is directed toovercoming, or at least reducing the effects of, one or more of theproblems set forth above.

BRIEF SUMMARY OF THE INVENTION

One aspect of the present invention is seen in a shipping containerincluding a first cover and a first load bearer. The first coverincludes sidewalls and a first plurality of ribs defined in thesidewalls. The first load bearer is positioned in a first pair of thefirst plurality of ribs and defines a first support surface.

These and other objects, advantages and aspects of the invention willbecome apparent from the following description. In the description,reference is made to the accompanying drawings which form a part hereof,and in which there is shown a preferred embodiment of the invention.Such embodiment does not necessarily represent the full scope of theinvention and reference is made, therefore, to the claims herein forinterpreting the scope of the invention.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The invention will hereafter be described with reference to theaccompanying drawings, wherein like reference numerals denote likeelements, and:

FIG. 1 is an isometric view of a shipping container in accordance withone illustrative embodiment of the present invention;

FIG. 2 is an isometric top view of a bottom cover of the shippingcontainer of FIG. 1;

FIGS. 3-6 are top, side, bottom, and end views of the cover of FIG. 3,respectively;

FIG. 7 is an isometric view of the shipping container of FIG. 1configured to house a larger load;

FIGS. 8 and 9 are side and end views of the shipping container of FIG.1, respectively;

FIGS. 10 and 11 are side and end views of the shipping container of FIG.1 in a stacked arrangement;

FIG. 12 is an isometric bottom view of the cover of FIG. 2;

FIGS. 13 and 14 are detail views illustrating a reinforcing frame;

FIG. 15 is an isometric view of a reinforcing frame;

FIGS. 16 and 17 are front and back views of a load bearer;

FIGS. 18, 19, and 20 are top, bottom, and end views of the load bearerof FIG. 16, respectively;

FIG. 21 is a detail view of an engagement tab on the load bearer of FIG.16;

FIGS. 22, 23, and 24 are isometric, top, and detail views, respectively,showing the engagement of a load bearer and a bottom cover in theshipping container of FIG. 1;

FIGS. 25 and 26 are isometric and detail views of the load bearer ofFIG. 16 illustrating interlocking tabs and pockets;

FIG. 27 is a front view of the load bearer of FIG. 16 illustrating asupport rod;

FIGS. 28 and 29 are front and back views of an alternative load bearerembodiment;

FIGS. 30, 31, and 32 are top, bottom, and end views of the load bearerof FIG. 28, respectively;

FIG. 33 is a detail view of an engagement tab on the load bearer of FIG.28;

FIGS. 34, 35, and 36 are isometric, top, and detail views, respectively,showing the engagement of a load bearer and a bottom cover in theshipping container of FIG. 1;

FIG. 37 is an end view of the shipping container of FIG. 1 with the loadbearer of FIG. 28 installed;

FIGS. 38 and 39 are isometric and detail views of a core support used inthe shipping container of FIG. 1;

FIGS. 40 and 41 are side and end views of the core support of FIG. 38;

FIG. 42 is an exploded isometric view of the core support of FIG. 28;

FIG. 43 is an isometric view of a latch used with the shipping containerof FIG. 1; and

FIG. 44 is a detail view of the latch of FIG. 43 engaging the covers ofthe shipping container of FIG. 1.

While the invention is susceptible to various modifications andalternative forms, specific embodiments thereof have been shown by wayof example in the drawings and are herein described in detail. It shouldbe understood, however, that the description herein of specificembodiments is not intended to limit the invention to the particularforms disclosed, but on the contrary, the intention is to cover allmodifications, equivalents, and alternatives falling within the spiritand scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

One or more specific embodiments of the present invention will bedescribed below. It should be appreciated that in the development of anysuch actual implementation, as in any engineering or design project,numerous implementation-specific decisions must be made to achieve thedevelopers' specific goals, such as compliance with system-related andbusiness related constraints, which may vary from one implementation toanother. Moreover, it should be appreciated that such a developmenteffort might be complex and time consuming, but would nevertheless be aroutine undertaking of design, fabrication, and manufacture for those ofordinary skill having the benefit of this disclosure.

Referring now to the drawings, wherein like reference numbers correspondto similar components throughout the several views, and, specifically,referring to FIG. 1, the present invention shall be described in thecontext of a shipping container 10. The shipping container 10 includes abottom cover 12 and a top cover 14. In the illustrated embodiment, thetop and bottom covers 12, 14 are identical. The use of identical covers12, 14 simplifies fabrication, storage, and assembly of the shippingcontainer 10, however, the invention is not limited to identical covers12, 14. The covers 12, 14 are further detailed in FIGS. 2-6, whichillustrate isometric, top, side, bottom, and end views, respectively.The shipping container 10 is assembled by mating the top and bottomcovers 12, 14 in an arrangement commonly referred to as a clamshellpackage. The covers 12, 14 may be fabricated using thermoforming, blowmolding, rotational molding, or injection molding processes.

Load bearers 16 are inserted into ribs 18 defined in the bottom cover12, and load bearers 20 are inserted into corresponding ribs 22 in thetop cover 14. The load bearers 16, 20 support a load 24 in the shippingcontainer 10. In the illustrated embodiment, the load 24 is a web ofmaterial, such as plastic film, paper, fabric, or mesh, wound about ahollow core 26 into which core supports 28 are inserted. In cases wherethe core 26 is solid or sufficiently rigid to support the load 24, thecore supports 28 may be omitted. For purposes of illustration, thefollowing description assumes that core supports 28 are inserted intothe ends of the core 26. The load 24, via the core supports 28, issupported by a support surface 30 defined in each load bearer 16. Thesize and shape of the support surface 30 may vary from the arcuate shapeillustrated, depending on the particular dimensions of the core 26. Thehorizontal spacing between the load bearers 16, 20 may be varieddepending on the size of the load 24, as shown in FIG. 7, whichillustrates the shipping container 10 accommodating a load 24′ that islarger than the load 24 shown in FIG. 1.

FIGS. 8 and 9 illustrate respective side and end views of the shippingcontainer 10 in an assembled state. The weight of the load 24 is carriedby the load bearers 16 to the base of the bottom cover 22. When multipleshipping containers 10 are stacked on top of one another, as shown inFIGS. 10 and 11, the load bearers 16, 20 carry a majority of the weightof the load 24.

The covers 12, 14 have pallet-style legs 32 that allow access for forktruck or pallet jack lifting from both sides and ends. The legs 32 maybe configured to interlock to allow positioning of one shippingcontainer 10 over another shipping container 10 for multiple levelstacking without risk of shifting when multiple shipping containers 10are moved. In the illustrated embodiment, the legs 32 are arranged indiagonally opposing corners, offset from the normal symmetry of thecover 12, such that when complete shipping containers 10 are stacked,the legs 32 on the top cover 14 pass the corresponding legs 32 on thebottom cover 14 of the stacked shipping container 10 to provide theinterlocking arrangement.

As seen in FIGS. 1 and 9, the covers 12, 14 may define one or moreopenings 34 in the ends 35 to allow spearing of the core 26 for loadingor unloading. The core support 28 may define a channel 36 for receivinga lifting device to allow such loading or unloading. The channel 36 mayhave a cross-sectional shape corresponding to the shape of the liftingdevice. For example, the lifting device may have a spearing device witha square cross section. A rectangular shape inhibits spinning of theload 24 during movement. Other cross-sectional shapes may be useddepending on the particular application.

Returning now to FIG. 2, the cover 12 is described in greater detail. Asthe top and bottom covers 12, 14 are similar, the description applies toboth. The sidewalls 38 of the cover 12 are tapered or drafted toaccommodate nesting together of empty covers 12. The ribs 18 defined inthe sidewalls 38 provide compressive strength and minimize deflection.The ribs 18 also provide a variety of positions for locating the loadbearers 16 and provide an interlocking mechanism for securing the loadbearers 16. The spacing between the ribs 18 may be varied to provide foradjustability of the load bearers 16 and to facilitate molding.

Turning to FIG. 12, which illustrates a bottom isometric view of thecover 12, a frame 40 may be provided for reinforcing the cover 12. FIGS.13 and 14 illustrate partial isometric views of the cover 12/frame 40assembly, and FIG. 15 illustrates an isometric view of the frame 40. Theframe 40 may be encapsulated in the cover 12 during the molded process(not shown) or inserted into tabs 42 defined in the cover 12. In theillustrated embodiment, the frame 40 is constructed of 0.25″ steel wireformed into a “double-H” configuration that includes two lateral members44 and two horizontal members 46. The frame 40 serves to distribute theload from the load bearers 16 evenly into the legs 32 of the cover 12regardless of the position of the load bearers 16. The frame 40 alsoprovides for minimizing the normal deflection of the shipping container10 when carried on a fork truck by transferring the load from theposition of the load bearers 16 to the position of the forks if they aredifferent. Additionally the shape of the frame 40 allows for a forktruck with forks slightly more than half the length of the shippingcontainer 10 to safely pick it up from the end 35 with minimumdeflection. It is contemplated that the frame 40 may have differentshapes, depending on the particular implementation.

Turning now to FIGS. 16 and 17 front and back views of a firstembodiment of the load bearer 16, are shown, respectively. Top andbottom views of the load bearer 16 are shown in FIGS. 18 and 19,respectively. An end view of the load bearer 16 is shown in FIG. 20. Theload bearer 16 includes a generally L-shaped tab 52, shown in detail inFIG. 21, that interlocks with the ribs 18 in the cover 12 to secure theload bearer 16 in place to support the load 24 and prevent outwarddeflection of the sidewalls 38 of the cover 12. In the illustratedembodiment, the load bearer 16 is constructed of a thermoplasticmaterial molding using a process such as twin sheet thermoforming, blowmolding, rotational molding, or injection molding.

FIGS. 22, 23, and 24, show isometric, top, and detail views of the loadbearer 16 interfacing with the bottom cover 12, respectively. The ribs18 include slots 54 having an L-shape corresponding to the shape of thetabs 52 on the load bearer 16. When the load bearer 16 is inserted intothe space defined by the ribs 18, the tabs 52 interlock with the slots54.

As seen in FIGS. 18 and 21, the tabs 52 of the load bearer 16 are offsetfrom the centerline of the support surface 30 by approximately one halfthe width of the ribs 18 formed in the sidewalls 38 of the cover 12 toprovide additional adjustability of the distance between the loadbearers 16. By reversing one or both sets of load bearers 16 in thecorresponding interlocking slots 54, a finer adjustment of the distancebetween the support surfaces 30 is achieved (i.e., as compared toselecting a different rib 18.

Returning to FIG. 16, the mating edge 56 of each load bearer 16 isprovided with interlocking tabs 58 of greater height than the partingline and are approximately one half the thickness of the load bearer 16.As seen in FIGS. 25 and 26, the interlocking tabs 58 fit intocorresponding pockets 60 defined on the opposite load bearer 16 thuskeeping the pair of load bearers 16 aligned when installed and underload. The load bearer 16 includes ribs 62 that carry and distribute theload. The ribs 62 run in a nearly vertical fashion and are positioned tocarry the weight of the contents to the reinforced area at the base ofthe cover 12 (e.g., the frame 40). The load bearer 16 also defines a tab64 along its bottom edge 66 that interfaces with a corresponding notch68 in the bottom surface 69 of the cover 12.

As shown in FIG. 27, in some embodiments, additional reinforcement maybe provided for the load bearer 16 by providing a support rod 71extending across the width of the load bearer 16. The support rod 71 maybe encapsulated in the load bearer 16 as it is formed, or,alternatively, a hole may be formed in an edged of the load bearer 16and the support rod 71 may be inserted in the annular region definedbetween the two walls of the support bearer 16. The support rod 71 islocated proximate the ends of the ribs 62 and below the support surface30. The ribs 62 formed on one side 73 of the load bearer 16 (see FIG.17) are offset with respect to the ribs 62 formed on the opposing side75 of the load bearer 16. The support rod 71 transfers the load placedon the support surface 30 to the ribs 62. The support rod 71 alsoprovides longitudinal stiffness for the load bearer 16 to reducedeflection. In the illustrated embodiment, the support rod 71 is atubular steel rod having a roughly square cross-section. It iscontemplated that other type of materials and shapes may be used,depending on the particular application.

Turning now to FIGS. 28 and 29 front and back views of a secondembodiment of the load bearer 70, are shown, respectively. Top andbottom views of the load bearer 70 are shown in FIGS. 30 and 31,respectively. An end view of the load bearer 70 is shown in FIG. 32. Theload bearer 70 includes a generally T-shaped tab 72, shown in detail inFIG. 33, that interlocks with the ribs 18 in the cover 12 to secure theload bearer 70 in place to support the load 24 and prevent outwarddeflection of the sidewalls 38 of the cover 12.

FIGS. 34, 35, and 36, show isometric, top, and detail views of the loadbearer 70 interfacing with the bottom cover 12, respectively. The ribs18 include slots 74 having a T-shape corresponding to the shape of thetabs 72 on the load bearer 70. When the load bearer 70 is inserted intothe space defined by the ribs 18, the tabs 72 interlock with the slots74.

As seen in FIGS. 30 and 33, the tabs 72 of the load bearer 70 are offsetfrom the centerline of the support surface 30 by approximately one halfthe width of the ribs 18 formed in the sidewalls 38 of the cover 12 toprovide additional adjustability of the distance between the loadbearers 70. By reversing one or both sets of load bearers 70 in thecorresponding interlocking slots 74, a finer adjustment of the distancebetween the support surfaces 30 is achieved (i.e., as compared toselecting a different rib 18.

Returning to FIG. 28, the mating edge 76 of each load bearer 16 isprovided with interlocking tabs 78 of greater height than the partingline and are approximately one half the thickness of the load bearer 70.The interlocking tabs 78 fit into corresponding pockets 80 defined onthe opposite load bearer 70 thus keeping the pair of load bearers 70aligned when installed and under load. The load bearer 70 includes ribs82 that carry and distribute the load. The ribs 82 run in a spokepattern to distribute the load in both vertical and axial directions.The load bearer 70 also defines a tab 84 along its bottom edge 85 thatinterfaces with the corresponding notch 68 in the bottom surface 69 ofthe cover 12.

As seen in FIGS. 28 and 37, the tab 72 one edge 86 of the load bearer 70extends beyond the mating edge 76 of the load bearer 70, such that italso extends above the top edge 88 of the bottom cover 12 to interlockwith slots 74 in the top cover 14. The tab 72 on the other edge 90 isreduced in height, such that it does not reach the top edge 88 of thebottom cover 12 to allow the extended tab 72 from the interfacing loadbearer 70 to extend from the top cover 14 into the bottom cover andengage the slot 74 in the bottom cover 12.

Although the load bearers 16 and 70 are described as separateembodiments, individual features of each may be combined. For example,the extended tab 72 feature on the load bearer 70 may be implemented onthe load bearer 16. The support rod 71 illustrated in the load bearer 16may be used in the load bearer 70. Also, the shape of the tabs 52, 72may vary. Other shapes, such as a dovetail shape, may be used in lieu ofthe “L” or “T” shaped tabs described herein. Also, the pattern formed bythe ribs 62, 82 may vary.

Turning now to FIGS. 38 and 39, the construction of the core supports 28is described in greater detail. The core support 28 includes a tab 92that interfaces with a corresponding notch 94 defined in the core 26 toprevent rotation of the core support 28 within the core 26 duringrotation. As seen in FIG. 40, the core support 28 may extend only aportion of the length of the core 26. FIG. 41 illustrates an end view ofthe core support 28 illustrating the square-shaped channel 36 forreceiving a lifting device to allow loading or unloading of the load 24.

Referring to FIG. 42, the core support 28 includes first and secondinterlocking member 96, 98 divided at a plane through the centerline ofthe core support 28. The core support members 96, 98 may be formed usinga twin sheet thermoforming process. Each member 96, 98 includes internalfeatures, such as the flat portions 100 that define the channel 36having a secondary sized and differently shaped opening through thecenter of the core support 28 to accommodates shafts of differentconfigurations used for transferring the load 24 once out of theshipping container 10 and on equipment used to process the product.

The core support members 96, 98 also include support structures 102,such as ribs, that provide compressive strength for supporting the load24. To interlock the members 96, 98 and prevent them from sliding oneach other, male bosses 104 and corresponding female receptors 106 aredefined on the mating faces of the members 96, 98.

Latches or straps of various styles may be used to hold the top andbottom cover 12, 14 together. An exemplary latch 110 is described inreference to FIGS. 43 and 44. The latch 110 includes an elastic body112, (e.g., a rubber “bungee”) and a “D” shaped ring 114 at one end 116of the body 112. The other end 118 of the latch 110 may be mounted(e.g., riveted or otherwise fastened) to the cover 12. A notch 120, oralternatively, an outwardly extending hook (not shown), may be definedin one of the ribs 18 of the other cover 14 to receive the ring 114. Thebody 112 may be stretched and placed in the notch 120 to hold the topand bottom covers together. The latch 110 is provided as one example ofa technique for coupling the top and bottom covers 12, 14. Although thelatch 110 is illustrated as being located a long one side of the cover12 near a rib 18, it is also contemplated that the latch 110 may belocated at corners of the cover 12. Other types of latches or couplingdevices may be used.

The shipping container 10 described herein provides a versatile systemthat can be adapted to loads of various shapes, sizes, and properties.The parts of the shipping container 10 may be stacked and storedreadily, and due to their durable construction and flexibility, they maybe re-used.

The particular embodiments disclosed above are illustrative only, as theinvention may be modified and practiced in different but equivalentmanners apparent to those skilled in the art having the benefit of theteachings herein. Furthermore, no limitations are intended to thedetails of construction or design herein shown, other than as describedin the claims below. It is therefore evident that the particularembodiments disclosed above may be altered or modified and all suchvariations are considered within the scope and spirit of the invention.Accordingly, the protection sought herein is as set forth in the claimsbelow.

1. A shipping container, comprising: a first cover including sidewallsand a first plurality of ribs defined in the sidewalls; and a first loadbearer positioned in a first pair of the first plurality of ribs anddefining a first support surface.
 2. The container of claim 1, furthercomprising a second cover disposed over the first cover to define anenclosure, the second cover including sidewalls and a second pluralityof ribs defined in the sidewalls.
 3. The container of claim 1, furthercomprising a second load bearer positioned in a second pair of the firstplurality of ribs and defining a second support surface.
 4. Thecontainer of claim 3, further comprising: a second cover disposed overthe first cover to define an enclosure, the second cover includingsidewalls and a second plurality of ribs defined in the sidewalls; athird load bearer positioned in a third pair of the second plurality ofribs and engaging the first load bearer; and a fourth load bearerpositioned in a fourth pair of the second plurality of ribs and engagingthe second load bearer.
 5. The container of claim 4, wherein each rib inthe first and second pluralities of ribs includes a slot portion, eachload bearer includes tabs having a shape corresponding to a shape of theslot portion and engaging the slot portion of a respective one of thefirst and second covers in which the load bearer is positioned, and atleast one of the tabs in each of the load bearers extends to interlockwith the slot portions of an opposing one of the first and secondcovers.
 6. The container of claim 4, wherein the first and second loadbearers each defines a first mating edge and a first tab extending fromthe first mating edge, and the second and third load bearers each definea second mating edge and a second tab extending from the second matingedge, the first tabs of first and second load bearers engaging thesecond tabs of the third and fourth load bearers, respectively.
 7. Thecontainer of claim 1, wherein each rib includes a slot portion, and thefirst load bearer includes tabs having a shape corresponding to a shapeof the slot portion that engages the slot portion to secure the firstload bearer within the first pair of ribs.
 8. The container of claim 7,wherein the tabs are offset with respect to the support surface of therespective first and second load bearer.
 9. The container of claim 1,wherein the first support surface comprises an arcuate support surface.10. The container of claim 1, wherein the first load member furthercomprises a lateral support rod disposed proximate the support surface.11. The container of claim 10, wherein the first load member furthercomprises at least one support rib abutting the lateral support rod. 12.The container of claim 1, wherein the first load member furthercomprises a plurality of support ribs proximate the support surface. 13.The container of claim 12, wherein the support ribs are disposed in atleast one of a vertical pattern and a spoke pattern.
 14. The containerof claim 1, further comprising a support frame engaged with the bottomcover, wherein the bottom cover encapsulates at least a portion of thesupport frame.
 15. The container of claim 1, wherein the first coverincludes a bottom surface and defines a notch in the bottom surface, andthe first support member includes a bottom edge and defines a tab alongthe bottom edge, the tab interfacing with the notch.
 16. The containerof claim 1, further comprising a load support operable to engage a loadand interface with the support surface to support the load.
 17. Thecontainer of claim 3, further comprising a load support including afirst portion extending from a first end of a load and engaging thefirst support surface and a second portion extending from a second endof the load and engaging the second support surface.
 18. The containerof claim 17, wherein the first and second portions comprises discretemembers.
 19. The container of claim 16, wherein the load includes a coredefining a notch, and the load support defines a tab, the tabinterfacing with the notch to inhibit rotation of the core about theload support.
 20. The container of claim 16, wherein the load supportdefines a channel operable to receive a lifting device having a shapecorresponding to the shape of the channel, and the first cover definesan opening aligned with the load support.